Editorial Contact:

Chuck Schroeder
Charleston|Orwig, Inc.
(262) 563-5056
cschroeder@comktg.com

SUB ARC PRODUCTIVITY IMPROVEMENTS GUARANTEED WITH NEW SUMMIT ARC 1000 POWER SOURCE

- Single wire, DCEP butt welds best candidates

- Standardize on single machine for all SAW applications

- Electrical efficiency for cost savings

APPLETON, Wis. (April 8, 2003) -

Miller Electric Mfg. Co. introduces the Summit Arc 1000 power source, a significant breakthrough in submerged arc welding (SAW) that offers a guaranteed improvement over DC electrode positive (DCEP) SAW.

“The Summit Arc 1000 features Miller’s exclusive variable balance AC squarewave submerged technology,” says Ken Fisher, manager of high deposition processes, Miller Electric. “This may increase deposition rates more than 50 percent over DCEP using the same welding parameters and wire types.”

Fisher adds that the Summit Arc 1000 can increase travel speeds to as much as 65 inches per minute and lower filler metal use by up to 42 percent. Other benefits to using the new power source include reduced heat input for minimized warping and base metal dilution and minimized magnetic arc blow and magnetization of weld fixtures and weldments.

Applications for the Summit Arc 1000 include shipbuilding, bridge construction, piping and other jobs where high travel speeds and repeatability are critical.

One Power Source for SAW

Innovative technology in the Summit Arc 1000 goes beyond its variable balance AC squarewave output. The machine provides alternating or direct current output in the constant current (CC) or constant voltage (CV) welding modes. Its unique configuration enables it to produce any type of SAW weld output. This enables plant managers to standardize on a single machine for all SAW applications, as well as shielded-metal arc and gas-metal arc welding (spray transfer only) and air carbon arc gouging.

The Summit Arc 1000 differs from other AC SAW power sources because it uses three-phase primary power, not single-phase. Three-phase power inherently creates a smoother weld output, and it lowers primary power use by nearly 30 percent.

At rated load —1000 amps at 44 volts, 100 percent duty cycle — the Summit Arc 1000 requires 100 amps of input power (575 V primary). A competitive single-phase AC SAW machine requires 146 amps of input power (575 V primary, 1200-amp rated load). The competitor also draws 25 amps while idling, while the Summit Arc 1000 draws just three amps at idle. Note that variable balance AC, CV squarewave for SAW has a completely different volt/amp curve than an AC squarewave for gas tungsten arc welding, which is a CC process.

Fisher notes that power savings of this magnitude should prompt fabricators with older AC SAW machines to consider upgrading their technology, as a new Summit Arc1000 could easily pay for itself in a few months. “The potential to reduce filler metal use, increase deposition rates and solve arc blow and other DC SAW problems all without changing welding parameters will cause many fabricators to consider replacing their old technology.”

The Summit Arc 1000 solves line notching and arc instability problems related to multiple torch applications with Miller Electric’s patented PhaseShift Technology, which allows two or more machines to coordinate AC wave polarities and guarantees a 60-degree offset between cycles. A synchronization terminal strip enables communication between power sources. Fisher points out the Summit Arc 1000 can be used as the second arc in a tandem sub-arc welding package.

The Summit Arc 1000 is covered by Miller Electric’s True Blue three-year factory warranty. To download a product spec sheet, visit Miller’s Web site at MillerWelds.com. To determine if the Summit Arc 1000 can improve productivity and lower weld cost in your operation, Miller Electric and its distributors will conduct a free SAW welding evaluation. For more information or the Miller distributor nearest you, call 800-4-A-MIILLER (800-426-4553), e-mail , fax 877-327-8132, visit the Web site or write to Miller Electric Mfg. Co., P.O. Box 100, Lithonia, GA 30058.

With headquarters in Appleton, Wis., Miller Electric Mfg. Co. is a leading worldwide manufacturer of Miller and Hobart brand arc welding equipment and related systems for metalworking, construction, maintenance and other applications. Miller Electric is a wholly owned subsidiary of Illinois Tool Works Inc. (ITW), Glenview, Ill. ITW is a diversified multinational manufacturer of highly engineered components, assemblies and systems.